komatsu wa1200 manual update10-1-12...folding stairway manual for komatsu wa 1200 psa-kom-wa1200-fs...

FOLDING STAIRWAY

Manual for Komat su WA 1200

PSA-KOM-WA1200-FS 30-8-18A

Model No.:PSA-WA1200-FSSerial No.:WA1200-FS-001C Date Manufactured:

CONTENTS

Page 3 Section 1 Installation and Mounting InstructionsInstallation Drawings

8 Section 2 Recommended Maintenance procedure

9 Section 3 Operating Procedure

Section 4 Drawings and Repair Parts lists

10 4 Assembly CompleteParts List

12 4-1 Base Frame and Mounting AssemblyParts List

14 4-2 Stair AssemblyParts List

16 4-3 Latch AssemblyParts List

18 4-4 Hydraulic CylinderParts List

Valve Diagram

21 4-5 Power Pack Parts List

25 4-6 Electrical ControlsParts ListsWiring Diagrams

Pg2PSA-KOM-WA1200-FS 30-8-18A

FOLDING STAIRWAYKomat su WA1200 Loader


Section 1 Installation and Mounting Instructions

As per Drawing PSA-W A1200-CW : Sheet 1 of 3 Page 4

Stair Mounting Pads Installation Procedure

1. Bolt on pads (CO2 + CO3) with the template (CO4) plate supplied. If they are not already done from factory. You may have to add extra washers as the bolts could be too long. VIEW X

2. Clean the paint where the weld will be applied, to avoid contamination.

3. Position the assembled template with pads in a way so that the pads faces sit with no clearance to the skin of the machine CW. The top lip of the template should sit on the top face of the OEM landing. VIEW Z

4. Check dimension is 305mm to the edge of the CW body as shown in VIEW Z. Tack weld pads to skin of CW.

5. Unbolt and remove template. Weld pads with an 8mm fillet all around. Follow welding procedure for cold weather.

As per Drawing PSA-W A1200-CW : Sheet 2 of 3 Page 5

Stair To Mounting Pads Installation Procedure

1. Fit base mounting plate (A01) against mounting pads and bolt firmly with the 8 BoltsM20x60 supplied.

2. Lift stair (in lowered position) and align 4 threaded bars and push firmly against base mounting plate. Insert washers and nuts to the threaded bar and tighten nuts firmly. Assure the rubber isolators are in place on the stair and fit the bolt supplied to fix them.

3. Fit extension steps as required to reach the minimum standard height from the ground.

NOTEFollow all on-site/Mine lif ting and safety procedures when inst allingPSFS to Loader



Section 1 Installation Instructions - Drawing PSA- WA1200-CW Sheet. 1Stair Mounting Pads See Procedure Pg. 3



Section 1 Installation Instructions Drawing PSA- WA1200-CW Sheet. 2Stair Mounting Pads See Procedure Pg. 3Floor and Handrails



Section 1 Installation Instructions - Drawing PSA- WA1200-CW Sheet. 3



Section 1 Installation and Mounting Instructions (cont.)


WARNINGRaising the POWER STEP platform by external means can create a vacuum in thehydraulic cylinder and create the opportunity to allow air into the hydraulic system,defeating the inherent safety features of the POWER STEP.This must be avoided, to maintain safe operation of the POWER STEP.

In instances where the use of external means to raise the platform must be used, please follow the following instructions:

Loosen hard plumbed hydraulic lines on cylinder side of lock valve on cylinder.Raise platform by available means.Note: Make necessary arrangements to collect displaced oil, and be aware that air entersthe piston side of the cylinder as platform is raised.Lock in raised position.Re-tighten hydraulic fittings.SECURE THE PLATFORM IN THE RAISED POSITION, MECHANICALLY, CHAIN &TAGOUT THE POWER STEP

To recommission the POWER STEP:

Loosen hydraulic fittings on cylinder side of lock valve.Note: Collect displaced oil.Lower platform to lowest position, using alternate safety approved means, fully retractingcylinder. Ensure all personnel are clear of step radius.Operate electrical control switch to purge air from the hydraulic line systems, lock valveand cylinder.Tighten the hydraulic fittings either side of lock valves to restriction fittings.Cycle step unloaded several times to purge all air from hydraulic system.The Power Step will not operate correctly if there is any air in the hydraulic circuit (due tothe incorrect operation of the lock valve).


Section 2 Recommended Maintenance Procedure

DailyVisually check st airway and structure for damage, loose component s, handrails, etc.

Check for hydraulic oil leaks from hydraulic cylinders, plumbing and hoses.

Notify the appropriate supervisor for any observed damage or malfunction.

500 HoursGrease 2 grease nipples on hinge pinsCheck main mounting bolts for torque.

Check hydraulic oil level in power pack and top up as necessary. (Stairway in raisedposition).

Top up using same hydraulic oil as used in hydraulics of machine.Thoroughly check all electrical wiring for damage, replace as necessary.

Repeat daily check as above

5000 HoursChange hydraulic oil in tank of hydraulic power pack (5.0 litres)

It is recommended that the same hydraulic oil be used in the power pack as the hydraulics of the machine.

Check and inspect all main bolts on stairway system.Retorque if required.

Repeat daily check as above



Section 3 Operating Procedure

To Lower S tairway (from the machine)Position machine in a level, safe area, away from the work face, whenever possible.Apply park brake and lower engine speed to idle.Check that the area below the Ladder Access System is clear of people and obstacles, and lower ladder by operating the two position electrical switch adjacent to the ladder, to the down position by pressing the switch down.Hold the switch in the down position until ladder is fully lowered.If the truck is parked on uneven ground, the bottom of the stairway may touch the ground before the ladder is in the fully lowered position.Should this occur, descend the ladder with caution.

To Raise S tairwayAscend the ladder onto the landing of the Loader.Ensure the area around the ladder is clear of people and standing to the side, clear of the area the handrails and ladder raises into, operate the electrical switch to the raise position (up).Hold the switch in the up position until the ladder is in the fully raised position.The ladder is now raised and stored.


OPERATING NOTES

NOTE: FLOW CONTROL VALVE ADJUSTMENT:The valve should be positioned to restrict the flow and speed of the Power Step whenlowering. Adjust the knob on top of the valve by turning left or right (clockwise) when thestep is being lowered, until it is lowering at a safe and reasonable speed.

When it is adjusted, lock the adjusting knob by tightening the grub screw located on theside of the knob.

NOTE: MAGNETIC 'GO' SWITCH ADJUSTMENT:The switch target trigger area is located on the opposite side and end from the cable entrypoint on the switch. Once it is mounted to the switch bracket, adjust the switch in or outfrom the stair steel trigger point, to be within 3mm - 10mm from touching each other whenthe stair is in the desired rest position.[DO NOT EXCEED 10MM DISTANCE BETWEEN THE SWITCH AND STRIKER PLATE].Test by raising and lowering the Power Step a couple of times and adjust again ifnecessary.



Section 4 Assembly Complete PSA-WA1200-FS


Section 4 Assembly Complete PSA-WA1200-FS

See Drawing Page 10


ITEM PART NO. PART NAME QTY

PSA-WA1200-FS ASSEMBLY COMPLETE 1

1 PS-23838-A STAIR BASE FRAME 1

2 PS-23851-A STAIR ASSEMBLY 1

3 PS-23847-A LATCH ASSEMBLY 1

4 PS-62996-A HYDRAULIC CYLINDERS (S tair) 1

5 PS-80103A-SLD POWER PACK 1



Section 4.1 Base Frame and Mounting Assembly PS-23838-ASee Parts List Pg. 13


Section 4.1 Base Frame and Mounting PS-23838-ASee Drawing Page 12


Item Part No. Part Name Qty

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

PS-23838

PSA-WA1200-C01

PSA-WA1200-C02

PSA-WA1200-C03

PS-23839

PS-23841-98

PS-23841-99

PS-23854

PS-23828

PS-23836-02

PS-23834-01

PS-23833-99

PS-23836-01

PS-23846-02

PS-23846-03-8

PS-23860

PS-1066553

PS-23834-03

PS-M20X250

CPS-M20X60ZP

CPS-M16X30ZP

CPS-M12X75ZP

CPS-M12X40ZP

CPS-M12X25ZP

CPS-M12X20ZP

CPS-M8X35ZP

CPS-M20NZP

PS-M12NZP

PS-M8NZP

CPS-M20WH

CPS-M16WH

CPS-M12WH

CPS-M8WH

PS-61002-2

BASE FRAME

BASE MOUNTING PLA TE

WELD PAD-OUTER

WELD PAD -INNER

TOP STAIR TREAD

STRIKER-LEFT SIDE

STRIKER-RIGHT SIDE

MANUAL RELEASE LEVER

HINGE PIN

SHEAR ISOLATOR ELEMENT

SHEAR ISOLATOR CAP

ISOLATOR COVER PLATE

FACE ISOLATOR ELEMENT

LATCH BUSH

RELEASE LEVER SPACER

LIFT LUG

LATCH LEVER BUFFER Mackay 12252555 M6

FACE ISOLATOR WASHER

THREADED ROD-M20 x 250

BOLT-M20 x 60

BOLT-M16 x 30

BOLT-M12 x 75

BOLT-M12 x 40

BOLT-M12 x 25

BOLT-M12 x 20

BOLT-M8 x 35

NUT-M20

NUT-M12

NUT-M8

WASHER-HARDENED-M20

WASHER-HARDENED-M16

WASHER-HARDENED-M12

WASHER-HARDENED-M8

GREASE NIPPLE

1

1

2

1

1

1

1

1

2

4

4

8

8

4

1

2

2

8

4

6

4

1

1

4

8

1

4

2

1

6

4

16

1

2

PS-23838-A (Inc.Items 1,5,6,7,8,9,10,11,12,13,14,15,17,18,22,23,24,25,26,27,28,29,32,33 & 34)


Section 4-2 Stair Assembly PS- 23851-ASee Parts List Page 15



Section 4-2 Stair Assembly PS- 23851-ASee Drawing Page 14



1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

PS-23852

PS-23862

PS-23863

PS-23849

PS-22266

PS-23839

PS-23857

PS-23848-07

PS-40002

PS-40003

PS-63009-B

PS-23862-05-3

PS-23865-LH

PS-23865-LH

CPS-M12X75ZP

CPS-M12X30ZP

CPS-M12X20ZP

CPS-M10X85ZP

CPS-M8X75ZP

CPS-M6X15ZP

CPS-M12NZP

CPS-M10NN

CPS-M8NN

CPS-M12WH

CPS-M10WH

CPS-M8WH

STAIR STILE (6 Tread)

STAIR HANDRAIL

HANDRAIL LINK POST

STAIR ACTUATOR BEAM

STAIR TREAD

STAIR TREAD -TOP

HINGE BUSH

BUMPER PAD

BUFFER-RUBBER-MACKA Y M12402055 M8

BUFFER-RUBBER-MACKA Y M12503555 M10

BUSH-Stair Actuator Beam

WASHER

STAIR EXTENSION-LEFT

STAIR EXTENSION-RIGHT

BOLT-M12 x 75

BOLT-M12 x 30

BOLT-M12 x 20

BOLT-M10 x 85

BOLT-M8 x 75

BOLT-M6 x 15

NUT-M12

NUT-NYLOC-M10

NUT-NYLOC-M8

WASHER-HARDENED-M12

WASHER-HARDENED-M10

WASHER-HARDENED-M8

1set

1set

1

1

7

1

2

2

2

2

1

4

1

1

4

16

20

4

2

4

4

6

6

36

4

2



Section 4-3 Latch Assembly PS-23847-ASSYSee Drawing Page 17


Section 4-3 Latch Assembly PS-23847-ASSYSee Drawing Page 16



1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

PS-62997

PS-23842

PS-23845-99

PS-23845-98

PS-23844-01-10

PS-23843

PS-23846-02

PS-23846-01

PS-23847

PS-23844-02-5

PS-S245

PS-75430

PS-M12X110ZP

CPS-M12X55ZP

CPS-M12X40ZP

CPS-M12X35ZP

CPS-M12X25ZP

CPS-M10X75ZP

CPS-M10X15ZP

CPS-M5X45ZP

CPS-M12NZP

CPS-M10NZP

CPS-M5NN

CPS-M12WH

CPS-M10WH

CPS-M5WH

CYLINDER

LATCH BASE

LATCH WRIST

ACTUATOR ARM

BOLT LINK

LATCH BOLT

LATCH BUSH

WRIST SPACER

SPRING

WASHER

LATCH BUSH-(WRIST PLATE) S245

PROXIMITY SWITCH

BOLT-M12 x 110

BOLT-M12 x 55 (Striker)

BOLT-M12 x 40

BOLT-M12 x 35

BOLT-M12 x 25

BOLT-M10 x 75

BOLT-M10 x 15

BOLT-M5 x 50

NUT-M12

NUT-M10

NUT-NYLOC-M5

WASHER-HARDENED-M12

WASHER-HARDENED-M10

WASHER-M5

1

1

1

1

2

2

6

2

2

4

2

1

1

1

4

1

4

2

4

2

1

6

2

12

6

2


Section 4-4 Hydraulic Cylinders and PlumbingCyl P/No. PS- 62996-AH

See Parts list Pg. 19 Latch Cyl PS- 62997-A



Section 4-4 Hydraulic Cylinders & PlumbingSee Drawing Pg. 18


STAIR & LA TCH CYLINDERS


1

-

2

-

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

PS-62996-A

PS-63103

PS-62997

PS-62997-SK

PS-23856

PS-63201

PS-61140

PS-61145

PS-61149

PS-61150

PS-61151

PS-61152

PS-61153

PS-61154

PS-61157

PS-61158-5mm

PS-61159

PS-61163

PS-61160

PS-60051-1.2M 9/16

PS-60050-1.2M 7/16

PS-60051-1.65M 9/16

PS-60050-1.8M 7/16

PS-60031-FT

HYDRAULIC CYLINDER ASSEMBLY

SEAL KIT-STAIR (NOT SHOWN)

HYDRAULIC CYLINDER - LA TCH

SEAL KIT-LATCH (NOT SHOWN)

CYLINDER PINS

VALVE - PILOT OPERATED LOCKING

FITTING-T -7/16”

FITTING - 9/16” JIC SWIVEL

FITTING - T 9/16”

FITTING - ELBOW 7/16”



FITTING - 1/4” BSPPx7/16” STRAIGHT

FITTING - ELBOW- O RING 1/4BSPPx9/16”JIC

FITTING - STRAIGHT 1/4”BSPPx9/16”JIC

FITTING - 5mm RESTRICTION 90 DEG

FITTING- ELBOW 9/16”

REDUCER JIC x BSPP

TUBE-900/1200

HOSE-HYDR. (9/16”JIC ST. SWIVEL 1.2M)




FERRULES

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

3

2

1

1

1

1

1

2

MOUNTINGS


1

2

PS-23855-98

PS-23855-02-5

PORT SHIELD PLATE

PORT SHIELD CLAMP

1

2

PS-62996-HPK-FS Hard Plumbing Kit (Items 4, 6, 9, 11 - 15, 17 & 22)


Section 4-4 Hydraulic Cylinder (Valve Diagram)


Double Acting Hydraulic System withdirectional Control Valve and Cylinder

Lock Valve


Section 4-5 Power Pack PS- 80103A-SLDSee Parts List Pg 23


9 9A 8

4

13

27

26 6 5 25

6

2 7

7A

10

29

11

16

14

12

3 3024 3A

3B

Hoses showndotted

View B View A

8A

FOLDING STAIRWAYKomat su WA1200 LoaderSection 4-5 Power Pack PS-80103A-SLDSee Parts List Pg 23

Pg22

View B

View A

32

33

24

14

19

11

16

28

NOTE.THE RELIEF PRESSURE OF THE POWERPACK IS TO BE SET TO 2800PSI.IF THE POWERPACK IS REPLACED,THIS RELIEF PRESSURE WILL NEED TO BERESET USING INLINE GAUGES.FAILURE TO DO SO MAY RESULT IN ACCIDENT OR INJURY

10

18

31

17

12

15

20

37

2123

9

9A

36

10

18



Section 4-5 Power Pack PS-80103A-SLDSee Photos Pg 21 & 22


1

2

3

3A

3B

4

5

6

7

7A

8

8A

9

9A

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

PS-80103A-SLD

PS-21107-METAL

PS-80103A

PS-80103-CLAMP

PS-84201-100

PS-82415

PS-84214

PS-82492

PS-60051-M/E Box 9/16”

PS-60050-M/E Box 7/16”

PS-61152

PS-61150

PS-61157

PS-61159

PS-84213

PS-84212

PS-84303

PS-1712080

PS-73012

PS-82493

PS-HD10-5-16P

PS-41010

PS-41011

PS-41012

PS-41013

PS-41014

PS-41023

PS-41024

PS-41041

PS-41019

PS-41017

PS-41018

PS-41016

PS-73010

POWER PACK ASSEMBLY

MOTOR ENCLOSURE- SEALED ST/ST

POWER PACK

CLAMP ELECTRIC MOTOR

HEAT SENSOR

AUDIBLE ALARM

BRIDGE RECTIFIER

SOLENOID 24V START MOTOR

HYDR. TUBE 9/16”

HYDR. TUBE 7/16”

HYDRAULIC FITTING 9/16”




135A CIRCUIT BREAKER

5A CIRCUIT BREAKER

ISOLATION SWITCH

SEALED WIRING BOX

TOGGLE SWITCH KIT

BATTERY FEED STUDS

5 PIN SOCKET

DECAL-Battery Isolation

DECAL-Battery Supply

DECAL-Controller Supply

DECAL-Battery Supply-PosItive

DECAL-Battery Supply-Negative

DECAL-Up/Down

DECAL HYDRAULIC-HOSES

DECAL OIL TANK

DECAL BRIDGE RECTIFIER

DECAL SOLENOID

DECAL ALARM

DECAL RAISE/LOWER SWITCH

RUBBER BOOT RED

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

6


Section 4-5 Power Pack PS-80103A-SLDSee Photos Pg 21 & 22



30

31

32

33

34

35

36

37

PS-73009

PS-HD10-3-16P

PS-HD10-5-16P

PS-41032

PS-60051-3.5M

PS-60050-3.5M

PS-63202A

PS-HD10-5-16P

RUBBER BOOT BLACK

3 PIN SOCKET (PARK BREAK)

5 PIN SOCKET (AUTO-RAISE)

DECAL AUTO-RAISE SOCKET

HYDRAULIC HOSE 9/16” x 3.5M

HYDRAULIC HOSE 7/16” x 3.5M

VALVE FITTING (FLOW CONTROL VALVE)

5 PIN SOCKET

3

1

1

1

1

1

1

1

Not Shown

Not Shown


Section 4-6 Electrical Controls


Cab Harness & EquipmentRefer Wiring Harness Drawings

Proximity Switch AssemblyMounted on Fixed Landing

Control Pendant SwitchMounted on Handrail

7

3

8

4 25 6

1


WARNINGLOW VOLTAGE BATTERIES WILL HARM THE FUNCTIONOF THE POWER PACK AND THE CONTROL SWITCHES.

DAMAGE RESULTING DUE TO LOW VOLTAGEBATTERIES WILL VOID WARRANTY ON ALL

ELECTRICAL COMPONENTS.


Section 4-6 Electrical ControlsSee Page 25


1

2

3

4

5

6

7

8

PS-73013

PS-73013-B

PS-77005

PS-77009AR

PS-77004

PS-75430

PS-77002

PS-77003

CONTROL PENDANT SWITCH

CONTROL PENDANT BRACKET

HAND RAIL SWITCH HARNESS

AUTO RAISE HARNESS

CABIN TO SWITCH HARNESS

PROXIMITY SWITCH

CABIN BOX LED LIGHT INDICA TOR

WIRING HARNESS IN CABIN

1

1

1

1

1

2

1

1

Optional only

1 x Optional



Section 4-6 Electrical System W iring Page 1



Section 4-6 Electrical System W iring Page 2W

IRIN

G H

AR

NE

SS



Section 4-6 Electrical System W iring Page 3.



Section 4-6 Electrical System W iring Page 4

WIRING HARNESS

komatsu wa1200 manual update10-1-12...folding stairway manual for komatsu wa 1200 psa-kom-wa1200-fs...

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